Controller housing with connector retention assembly and method

ABSTRACT

A method and a housing assembly including a case defining an opening, and a coupler positioned within the opening and configured for coupling to a connector, wherein the case defines a securing portion positioned proximate to the opening and is configured for securing a portion of the connector when coupled with the coupler.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/670,078, filed on Apr. 11, 2005. The disclosure of the aboveprovisional application is incorporated herein by reference.

FIELD

The present invention relates to power control systems, and morespecifically, the invention relates to a housing for a power controller.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

Generally, typical power control installations require selection of thediscrete components, customized mounting and wiring for each componentand feature, and numerous connections. One example of such a powercontrol installation is a control system application for controlling thepower provided to a power-receiving load where the power receiving loadis a heater supplying heat to a temperature controlled manufacturingprocess. Any changes, additions, modifications, and replacements requiredisconnection and reconnection of various wire leads, yet againincreasing the opportunity for problems. For example, the wire leads areoften contained within wiring assemblies and terminated in wireconnectors. These connectors often include a retaining clip or otherretaining mechanism that are subject to premature failure when subjectedto repeated connections and disconnections. The failure of the connectorretention clips can result in the production system having to be haltedand the failed components replaced by operating system maintenancepersonnel. Costly downtime and loss in process yields can result fromsuch premature component failures. It is desirable to eliminatecomponents that can succumb to premature failures.

The aforementioned problems and limitations of the existing power andthermal control systems and connectors are recognized by the inventorshereof and some or all of these limitations have been addressed byvarious embodiments of the current invention.

SUMMARY

The inventors hereof have succeeded at designing a power controllerhousing and method of operation wherein the power controller housingaids in the reduction and possibly the elimination of the failure of aconnection between a connector connected to the power controller and thepower control system.

According to one aspect of the invention, a housing assembly has a casedefining an opening, and a coupler positioned within the opening andconfigured for coupling to a connector. The case defines a securingportion positioned proximate to the opening and is configured forsecuring a portion of the connector when coupled with the coupler.

According to another aspect of the invention, a power control system hasa power switch for selectively providing at least a portion of powerreceived from a power source to a power load in response to a controllerincluding a coupler for coupling to an external connector. A housingencloses the controller and the power switch and defines a coupleropening for external access to the coupler. The housing has a biasingportion located proximate to the coupler opening for providing a biasingforce to an engaging portion of a connector when the connector iscoupled with the coupler. The biasing portion is configured to securethe connector in the coupled position with the coupler.

According to yet another aspect of the invention, a housing assembly hasa case defining an opening, a coupler positioned within the opening andconfigured for coupling to a connector. The assembly includes means forsecuring the connector to the coupler following coupling of theconnector with the coupler.

According to still another aspect of the invention, a power controlsystem has a power switch for selectively providing at least a portionof power received from a power source to a power load in response to acontroller. A coupler is configured for coupling to a connector. Ahousing is configured for enclosing the controller and the power switchand defining an opening. The coupler is positioned within the opening.The system includes means for securing the connector to the couplerfollowing insertion of the connector within the opening and coupling ofthe connector with the coupler.

According to still another aspect of the invention, a method ofoperating a power controller having a housing enclosing a power switchfor receiving power from a power source and selectively providing atleast a portion of the received power to a power load includes insertinga connector into an opening defined by the housing enclosing the powerswitch and the controller, flexing a securing portion of the housingproximate to the opening during the inserting of the connector into theopening, and coupling the connector to a coupler positioned within theopening. The method also includes securing the securing portion of thehousing against a locking portion of the connector following coupling ofthe connector to the coupler.

Further aspects of the present invention will be in part apparent and inpart pointed out below. It should be understood that various aspects ofthe invention may be implemented individually or in combination with oneanother. It should also be understood that the detailed description anddrawings, while indicating certain exemplary embodiments of theinvention, are intended for purposes of illustration only and should notbe construed as limiting the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram illustrating an industrial process operatingenvironment having a heater under the control of a power control systemfor monitoring and maintaining a temperature of the process according toone exemplary operating environment for some embodiments of theinvention as described herein.

FIG. 2 is an isometric view of a mounting assembly for mounting anelectrical device in an operating environment according to one exemplaryembodiment of the invention.

FIG. 3 is an isometric view of a mounting bracket for an electronicdevice according to one exemplary embodiment of the invention.

FIG. 4 is a front view of a mounting bracket according to one exemplaryembodiment of the invention.

FIG. 5 is a top view of a mounting bracket configured for electronicdevice mounting according to one exemplary embodiment of the invention.

FIG. 6 is a side view of a mounting bracket illustrating the offset ofthe mounting bracket base and coupling elements according to oneexemplary embodiment of the invention.

FIG. 7 is an isometric view of an electronic device housing illustratingan integrated mounting coupler with a coupling interface configured formounting the electronic device in an operating environment according toone exemplary embodiment of the invention.

FIG. 8 is a top view of a housing for an electronic device having anintegrated mounting coupler for releasably receiving a mounting bracketaccording to one exemplary embodiment of the invention.

FIG. 9 is a lengthwise side view of a power controller housingillustrating a connector cavity for accommodating a quickconnect/disconnect connector for a power/control cable and ventilationports according to one exemplary embodiment of the invention.

FIG. 10 is an end view of the power controller housing illustratinganother connector cavity for accommodating a quick connect/disconnectconnector for a power/control cable according to another exemplaryembodiment of the invention.

FIG. 11 is a side view of a DIN rail electronic device mounting couplerand bracket according to another exemplary embodiment of the invention.

FIG. 12 is a side view of a panel mounted electronic device mountingcoupler and bracket according to another exemplary embodiment of theinvention.

FIG. 13 is an isometric view of a power control system illustrating thedigital temperature display with scrolling controls, the asynchronouscommunications interface jack receptacles and thequick-connect/disconnect power cable interfaces according to oneexemplary embodiment of the invention.

FIG. 14 is another isometric view of a power control system illustratinga bottom housing section connected to a mounting device and ventilationportals according to another exemplary embodiment of the invention.

FIG. 15 is an isometric view of a top half housing of a power controlsystem illustrating a releasable user interface module according to oneexemplary embodiment of the invention.

FIG. 16 is a bottom isometric view of a top half housing of a powercontrol system illustrating the three connecting tabs to the lower half,the serial communications interface jack receptacles and the bottom ofthe printed circuit board hosting the display control electronicsaccording to one exemplary embodiment of the invention.

FIG. 17 is an isometric view of another embodiment of the power controlsystem with a cover positioned on a control system housing in theabsence of a pluggable user interface according to one exemplaryembodiment of the invention.

FIG. 18 is a side view of the user interface module showing thecommunications jacks and the plug interface to a lower half housingaccording to one embodiment of the invention.

FIG. 19 is an isometric view of a quick-connect connector and thequick-connect receptacle that interfaces the power and control signalsbetween a power load and the power controller according to one exemplaryembodiment of the invention.

FIG. 20 is an isometric view of the power control system controllerillustrating a quick connect receptacle with a locking tab ramp and itsassociated compressive retaining cam surface that provides a compressiveforce to a connector lever arm according to one exemplary embodiment ofthe invention.

FIG. 21 is another isometric view and embodiment of a compressiveretaining cam surface according to one exemplary embodiment of theinvention.

FIG. 22 is a block diagram of a controller system and its varioussub-components for a power controller as described herein and as inaccordance with one exemplary embodiment of the invention.

FIG. 23 is an isometric view of a power controller with two connectorscoupled to couplers and secured by a securing portion of the controllerhousing according to one exemplary embodiment of the invention.

FIG. 24 is an isometric view of a Molex® Minifit Jr.® connector suitablefor coupling with the coupler and secured by the controller housing inaccordance with some exemplary embodiments of the invention.

FIG. 25 is a side isometric view of a connector coupled to a coupler ofa power controller with a top half of the case removed in accordancewith one exemplary embodiment of the invention.

FIG. 26 is a side isometric view of the connector coupled to the couplerof the power controller of FIG. 25 showing the top half of the case butwith the lower half removed in accordance with one exemplary embodimentof the invention.

FIG. 27 is a schematic view of one exemplary embodiment of a powercontroller.

Like reference symbols indicate like elements or features throughout thedrawings.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is in no wayintended to limit the invention, this disclosure or its applications oruses.

Power Controller Operating Environment

FIG. 1 illustrates, by way of example, a power control systemenvironment 100 applicable with one or more of the various embodimentsof the present disclosure. In FIG. 1, a thermal process includes threeprocesses A 102, B 104 and C 106 with process B 104 requiring theheating of materials prior to proceeding to process C 106. Such anexemplary manufacturing process 100 can include, by way of example, aplastics or semiconductor manufacturing process. In this example, thetemperature of process B 104 is monitored by a sensor (not shown) andthe monitored temperature is provided in a sensor signal to a powercontroller or power control system 108. The power control systemreceives the monitored temperature and generates heater control signals110, which may be in the form of power, to control a heater 111 toprovide a desired temperature or temperature range for process B 104.

A human machine interface (HMI) system provides for user monitoring anduser intervention to the control system 108. This can include displayingone or more operating characteristics of the control system 108 and userinput mechanisms, such as keys or buttons, by way example, therebyproviding the interface to the process operator for monitoring andmodifying temperature control parameters. For example, in a thermalprocess as shown in FIG. 1, this can include inputting temperatures orset points and displaying or producing an in-range indication or a highor low temperature alert indication.

Electronic Device Mounting Assembly

In some embodiments, a bracket for mounting an electronic device in anoperating environment has a mounting flange configured for attachment toa surface within the operating environment and a securing flange havinga surface and one or more securing tabs offset from the surface andpositioned about a periphery of the surface. The securing flange isconfigured for coupling to a corresponding mounting coupler attached tothe electronic device with less than a full turn of the mounting couplerrelative to the securing flange. An offset portion couples the mountingflange to the securing surface and defines an offset therebetween. Thebracket can be configured as a unified body made of a metal or a plasticor may be assembled from a plurality of parts. The mounting flange canbe relatively flat or can be curved or shaped to adapt to a particulartype of mounting surface, such as having a convex curved shape formounting to a pipe.

The mounting flange can be configured to be attached to the mountingsurface by a variety of attachment or mounting fasteners and/orfastening arrangements. The mounting flange can be adapted forattachment by a strap, a cable tie, a screw, a DIN rail mount, and abolt, by way of example. For example, the bracket can include mountingholes for attaching the bracket to a mounting surface with one or morefasteners such as a screw, a bolt, or a rivet. In other embodiments, thebracket can include a mounting sleeve for receiving a mounting strap, acable, or a cable tie. In other embodiments, the bracket can beconfigured for bonding or adhesion to the mounting surface. In yet otherembodiments, the bracket can be configured as an integrated portion of amounting surface, such as a panel, a DIN rail, another electronic devicehousing, a pipe strap, or an external portion of another electronicdevice.

Additionally, the mounting flange can be adapted for mounting in anyposition, vertical, horizontal, upright, or upside down, or anyvariation thereof, for mounting an electronic device in a flexiblemounting position adapted for the particular requirements of theapplication of the electronic device. This can be very desirable as itcan enable the mounting of the electronic device in proximity to anotherelectronic device or an operation or associated process or function. Forexample, a power controller providing power to a power load such as aheater, can have the bracket configured for mounting in close proximityto the heater such that the power controller can be coupled thereto andalso in close proximity. Such a power controller can be configured witha housing enclosing one or more of a power switch, a controller, and alimiter configured for selectively providing power to the heater oranother power load.

One or more securing tabs of the securing flange can be offset from thesurface of the surface of the securing flange such as in the directionopposing the mounting flange and the offset portion. In otherembodiments, one or more securing tabs may be offset in the directiontowards the mounting flange. In other embodiments, the securing tabs canbe formed on an outer periphery of a circular or otherwise shapedsurface but in the same plane as the surface. In some embodiments, thesecuring tabs and the securing surface are each configured to engage aportion of a securing surface of the mounting coupler and can beconfigured to capture a portion of the securing surface between anoffset securing tab and the surface to provide a securing engagement ofthe coupler securing portion of the mounting coupler.

The number of securing tabs can be of any number from one or moredepending on the particular design considerations for a coupling with amounting coupler in less than a full turn. For example, a single tab mayenable a coupling turn up to nearly a full turn, whereas two securingtabs would enable a coupling turn of 180 degrees or less. In onepreferred embodiment, there are three securing tabs and couplingrotation is equal to or less than about 120 degrees. In anotherpreferred embodiment, there are four securing tabs and the couplingrotation is equal to or less than about 90 degrees. An additionalpreferred embodiment, would provide for a coupling rotation of less than45 degrees. This latter embodiment, can provide for a desired orimproved coupling and decoupling of an electronic device wherein theelectronic device is connected to one or more wires or is mounted in arelatively tight operating space. Of course additional securing tabs canreduce the coupling rotation and are still considered to be within thescope of the present disclosure.

In some embodiments, an assembly for mounting an electronic device in anoperating environment including a bracket and a coupler. The bracket hasa mounting flange configured for attachment to a surface within theoperating environment for mounting the electronic device, a securingflange with a surface, and a plurality of securing tabs offset from thesecuring flange surface and positioned about a periphery of the surface.The bracket also includes an offset portion coupling the mounting flangeto the securing surface and defining an offset therebetween. The coupleris configured for coupling to the securing flange of the bracket. Thesecuring flange of the bracket and the coupler are configured forreleasably coupling with less than a full turn relative to each other.

The coupler can be configured in any shape and can be oriented as a maleor female coupler to engage an appropriate female or male orientedmounting bracket. For example, the mounting bracket can be configured ashaving a male oriented circular securing surface and the coupler wouldbe configured with a corresponding female oriented circular cavity forreceiving the mounting bracket. The coupler can include one or morereceiving channels coupled to each of the receiving cavities forchanneling one of the securing tabs of the mounting bracket. In someembodiments, one or more receiving channels can have an angled surfaceconfigured for engaging one of the securing tabs when inserted androtated within the associated receiving cavity. In this manner, uponengagement of the bracket and the coupler and a rotation of the couplerrelative to the bracket, a securing tab of the bracket traverses thereceiving channel and engages the angled surface to provide an inwardbias to engage and secure the securing tab and therefore to secure thebracket to the coupler.

In some embodiments, the coupler is configured from a plastic or metalas a unitary body and adapted for attachment or engagement with anelectronic device or the housing enclosing an electronic device. Inother embodiments, the coupler can be defined or integrated within anelectronic device housing such as molded into an outer surface of aplastic case or housing.

In some embodiments, a method of mounting an electronic device in anoperating environment includes attaching a bracket to a surface withinthe operating environment, and releasably coupling a housing enclosingthe electronic device to the attached bracket, the releasably couplingincluding a rotation of the housing relative to the attached bracket ofless than a full turn. This can also include attaching the bracket witha cable tie through a mounting sleeve of the bracket and securing thecable tie about a mounting structure with the operating environmentdefining the surface. In other embodiments, the method can includeattaching the bracket via a DIN rail attachment or attaching the bracketwith one or more screws, bolts or rivets.

Referring now to FIG. 2, a power control system 200 illustrates oneexemplary embodiment of an electronic device mounting assembly having acontrol housing 202 with a mounting coupler 204 configured forreleasably coupling to a mounting bracket 206. In this exemplaryembodiment, the mounting coupler 204 is integrated into a housing base214 of the control housing 202 and has a coupler cavity 218 forreceiving a portion of the mounting bracket 206. It should be understoodthat in other embodiments, the mounting coupler 204 can be configured asa separate non-integrated fixture attachable to any electronic componentor device for mounting the electronic device to an operating environmentfor the electronic device. The mounting bracket 206 is adapted to mountto a portion of the operating environment in which the electronic deviceis desired to be mounted. This can often be a harsh or abnormal mountingenvironment or position, and is enabled by the flexibility of themounting bracket 206 and its inter-coupling with the mounting coupler204. The mounting coupler 204 and mounting bracket 206 are configuredfor multiple coupling and uncoupling with simple user interaction whilestill ensuring a secure mounting of the electronic device when coupled.

In the exemplary embodiment of FIG. 2, the mounting coupler 204 isconfigured with the coupler cavity 218 having a plurality of receivingcavities 220 positioned about the perimeter of the coupler cavity 218.Each receiving cavity 220 is configured for receiving a tab 306 of themounting bracket 206. The mounting coupler 204 includes a securingchannel 222 defined by a securing structure 228. Additionally, thesecuring channel 222 can include a beveled or angled portion 224 to aidin receiving the tab 306 into the securing channel 222. A securingportion is defined by the securing channel 222 and an outer securingsurface 229 on the exterior of the coupler 204 opposite to the securingchannel 222.

The mounting bracket 206 includes an interlocking portion 305 thatincludes the tabs 306 and an engaging surface 302. The tabs 306 and theengaging surface 302 are adapted such that the tabs 306 can be receivedby the receiving cavity 218 and, upon rotation of the mounting coupler204 and/or the mounting bracket 206, are received within the securingchannels 222. Upon the securing rotation, the securing structure 228defined by the securing channel 222 and the securing surface 229 issecured between the tabs 306 and engaging surface 302 thereby securingthe mounting bracket 206 to the mounting coupler 204.

In FIG. 2, the interlocking portion 305 is a circular structure butcould have different shapes in other embodiments. Additionally, itshould be understood that while the illustrated embodiment reflects themounting coupler 204 being mounted on the electronic device and being afemale and the mounting bracket 206 being mounting to the operatingenvironment and being male, in other embodiments the mounting bracket206 can be configured with the female receiving cavity and the mountingcoupler 204 can be configured with the male portions and still be withinthe scope of the present disclosure. e.g., the interlocking portion ofthe mounting bracket 206 can be male or female and the interlockingportion of the mounting coupler 204 can be female or males.

The mounting bracket 206 can be mounting within the operatingenvironment in a variety of manners and with a variety of mountingfixtures. The mounting bracket 206 includes a mounting base 301 that isoffset from the mounting structure 305 by an offset portion to aid inthe mounting of the electronic device and to create an offset spacebetween the engaging structure 305 and the mounting base 301, andtherefore between the electronic device and the surface or structure onwhich the mounting bracket 206 is attached. The mounting bracket 206 canbe adapted for mounting using screws, bolts, rivets, or similarattachment fixtures by one or more mounting holes 210 defined by themounting bracket 206. In other embodiments, the mounting bracket 206 caninclude one or more mounting sleeves 212 for receiving and securing amounting cable or cable tie (not shown). In various other embodiments,as illustrated by way of additional example in FIGS. 11 and 12, themounting bracket 206 can be adapted for mounting via a DIN Rail fixtureas in FIG. 11 or to an electronic panel as in FIG. 12.

Generally, the mounting coupler 204 and mounting bracket 206 areconfigured to inter-work to engage and mount the electronic device witha securing rotation of the user of less than a full turn. In someembodiments, this can be about equal to or less that a 120 degreerotation, for example in an embodiment having three tabs 306 and threereceiving cavities 220. In other embodiments, as shown in FIG. 2, thesecuring rotation can be about equal to or less than about a quarterturn or 90 degrees where the mounting bracket 206 has four tabs 306 andthe mounting coupler has four receiving cavities 220. Of course, asknown to those skilled in the art, more or less numbers of tabs 306 andreceiving cavities 220 can be utilized and provide a different securingrotational amount and still be within the scope of the disclosure.

By way of further examples, FIGS. 3-6 illustrate different views of amounting bracket 206 that are capable of mounting and securingelectronic devices, such as power controllers, in operating environmentssuch as processing systems including thermal processes. It should benoted that the dimensions and adaptations of these figures are onlyshown by way of example and should not be construed to limit its scopeor implementation as other applications may require other dimensions.

In FIGS. 3-6, this exemplary embodiment of the mounting bracket 206includes two mounting holes 210 for mounting the bracket 206 on asurface 302 with a fastener (not shown). The mounting bracket 206includes engaging surface 302 that is offset from a mounting base 301 byan offset portion 303 to provide a keying element. The engaging surface302, shown as a circle but that can be of any shape, can have sectorextensions by the engaging surface 302, each defining a sector gap 304therebetween. Attached to the engaging surface 302 are four securingtabs 306 dimensioned that can have a greater, equal to or lesser radialsize than the sector gaps 304. The combination of the tabs 306 that areoffset from the engaging surface 302 and the surface 302 serve as akeying lock for the coupler 214 such that when the keying interfaces ofthe coupler 214 are aligned with the securing tabs 306 and pressedagainst the engaging surface 302, the controller 200 or the housing 202can be rotated relative to the bracket 206 to lock the controller 200 tothe mounting bracket 206. In this particular embodiment, the mountingand locking rotation requires no more than 90 degrees of rotation as thetabs 306 are spaced at 90 degree positions. However, in otherembodiments, such as one have only two tabs 306 spaced 180 degrees apartor three tabs 306 spaced 120 degrees apart, by way of example, themounting and locking rotation may be different as suitable for sucharrangements. Of course, the mounting and locking rotation can be infewer degrees than the actual radial spacing between two consecutivetabs 306.

FIGS. 7 and 8 are two views of an electronic device housing 700 havingan integrated mounting coupler (such as coupler 204). FIG. 7 is anisometric view of the lower half of the housing 702 for an electronicdevice such as a power controller. This includes ventilation ports 704that facilitate ambient air circulation for cooling the housedelectronics and connector cavities or connector cavities 706 thataccommodate connectors for coupling to external systems such as powerconductors, communication conductors, and sensor or signal connectors.In this exemplary embodiment, the mounting coupler 204 is integrallyformed by lower housing 702 is centrally positioned on the bottomsurface of the lower housing 700. The mounting coupler 204 is configuredfor coupling with a rotational interlocking interface 708 that isadapted for receiving a mounting bracket, such a mounting bracket 206 or301 as shown in the examples of FIG. 3-6.

FIG. 8 is a top view illustrating the central location and fixture 802configured as a coupler with a base keying element for receiving amounting bracket 206, or a portion thereof. FIG. 9 is a lengthwise sideview of the lower housing 702 illustrating its compact dimensions, theventilation ports 704 and the side connector cavity 706 configured toaccommodate a mini-jack connector on a printed circuit board. FIG. 10 isa side end view further illustrating the ventilation ports 704.

FIGS. 11 and 12 are side views of two other implementations for mountingbrackets. FIG. 11 illustrates an electronic device mounting assembly1100 configured with a DIN rail 1102 implementation of the mountingbracket 206 and the mounting of the power control system 202 on a DINrail 1102 according to another embodiment of the invention. FIG. 12illustrates an electronic device mounting assembly 1200 showing a sideview illustrating a panel mounted implementation of the mounting bracket206 for mounting the power control system 202 on a panel 1202 or panelarrangement according to another embodiment of the invention.

Power Control System

A power control system according to one exemplary embodiment of thepresent disclosure has been designed to overcome the premature failureof a thermal fuse contained within a heater and thereby eliminating theneed for a thermal fuse. Premature thermal fuse failure can occur whenhigh process temperature requirements expose the fuse to temperaturesthat degrade the internal materials of the fuse over time to the pointthat the heater unit opens prematurely, rendering the heater inoperableand disabling the manufacturing process. High temperature processtransients (e.g., hot exhaust gases) may also contribute to prematurethermal fuse failure within the heater.

In one embodiment, a power control system has a controller housing witha power switch disposed within the controller housing for selectivelyproviding power from a power supply to a power load. A limiter, such asa safety limiter, is also disposed within the controller housing and isconfigured for providing a limit switching function in response to athreshold limit. A controller is also disposed within the controllerhousing and is configured for controlling one or more operations of thecontrol system. This is in contrast to existing systems where thelimiter is deployed as a separate and distinct component from the powerswitch and controller. Additionally, in some embodiments, a userinterface module can be mounted on or within the controller housing fordisplaying parameters or messages to a user and to receiving inputs fromthe user, such as user specified threshold limits, selection of a sensortype, or selection of a power switch control profile.

The controller housing includes a case with an internal cavity forreceiving and enclosing the power switch, the limiter and the controllertherein. The controller housing generally can include thermal ventingports positioned about the periphery of the controller housing to enableambient airflow through the thermal venting ports and about the limiterand power switch within the controller housing.

Referring now to FIG. 13, one example of a control system or controller1300 is illustrated and includes a user interface assembly 1302 having auser interface housing 1303 connected to a controller housing 1304. Thehousings 1303 and 1304 function as protective environmental shells forthe electronic components housed therein. The controller housing 1304has connector cavities 706 to accommodatequick-connect/quick-disconnected couplers or connectors 1306, such as aMolex® Minifit Jr.® (registered trademark of Molex) connector, tofacilitate a quick connect and disconnect of the power/control cables toa coupled load such as a heater. Ventilation ports or cutouts 704 areprovided in the bottom portion to provide portals for facilitating thecirculation of ambient air to cool the electronics housed within thecontroller 1300.

Additionally, to aid in mounting of the controller 1300 in the operatingenvironment, the controller housing 1304 can include or have attached amounting coupler (not shown) configured for coupling to a mountingbracket (not shown) but as described above by way of example.

The controller housing 1304, or a user interface assembly 1302associated therewith, can also include one or more visual statusindicators 1308 configured to provide a different operational status ofthe power controller 1300. For example, a first visual status indicator1308 can be indicative of an output of the controller 1300, a secondvisual status indicator 1308 can be indicative of an in-range systemoperation of the controller 1300, and a third visual status indicator1308 can be indicative of an exceeded range of operation of thecontroller 1300. In another embodiment, an active red colored LED can beused to visually indicate a high or low temperature alert or may be aflashing red LED signal. A second steady state active amber LED canserve as a visual indication of an in-range temperature operation. Thethird LED can be of a green color to indicate that the controller 1300is actively supplying input power to its associated heater. Thus, whenthe power controller 1300 is not providing power to the heater, thegreen LED is inactive.

More or fewer visual status indicators 1308, such as lights or LEDs, canhave one or more colors indicative of a different status of the powercontroller 1300. The visual indicators 1308 can be programmed or wiredto be indicative of any desired controller functionality or status. Inanother embodiment, the controller display visual indicators, such asLEDs, are configured to flash to provide an indication of the identityof a specific controller within a series of controllers within a processfacility. The flashing of these indicators can be in response to acontroller receiving a request to identify itself, as received from aremote operational system. In such embodiments, a central operatingsystem can “ping” the address of a controller and trigger a flashing LEDresponse (e.g., “here I am”) to assist operations personnel in locatingthe controller. Such applications require each controller 1300 to beequipped with a display controller interface. In other cases, the userinterface assembly 1302 or controller 1300 can be configured with anaudio output device (not shown) for providing an audio notification oridentification signal in response to the request to identify. In otherembodiments, the controller 1300 and/or the user interface assembly 1302can be configured with a system identification module (not shown)capable of generating a system identification signal or message over thedata communication interface.

The controller housing 1304 and/or user interface housing 1303 can be ofcompact size that can be easily mounted in an operating or processingarea close to the power load. For instance, the power controller couldprovide controlled power to a heating element in a processing system. Insuch an application, a compact integrated power controller 1300 caninclude an integrated limiter, such as a safety limiter, can be placedvery near a heating element. While the relative compactness of the powercontroller 1300 can vary depending on the power delivery requirements,as is known to those skilled in the art, in one exemplary embodiment,the controller housing 1304 has a total externally defined shapedefining an external maximum dimensions defining a volume of less thanor equal to about 24 cubic inches. For example, in one implementedembodiment, an exemplary power controller 1300, as shown in FIG. 2, hasthe dimension in inches of 3.496×1.582×2.196 without a mounting bracket.As will also be discussed, the power controller 1300 can also include auser interface assembly 1302 having a user interface housing 1303. Insuch embodiments, one exemplary embodiment can have dimensions in inchesof 3.496×2.503×2.196. Of course, it should be understood that otherdimensions and shapes can also be implemented and still be consideredwithin the scope of the present disclosure.

In another embodiment, the power control system includes a first couplerconfigured for receiving power from a power source and a second couplerconfigured for providing power to the power load. In one embodiment, thefirst coupler is configured for providing a temperature alarm signalindicative of an alarm condition of the system and/or the second coupleris configured for receiving a temperature signal from a temperaturesensor. In some embodiments, the second coupler is configured forreceiving a plurality of temperature signals from a plurality oftemperature sensors. Additionally, in some multi-coupler embodimentseach coupler can be color coded to aid in the use of the system. Forexample, a first coupler and a second coupler are color coded toindicate one as an input coupler and one as an output coupler. In oneembodiment, the first coupler is colored black and is configured as aninput from a power source. The second coupler is colored white and isconfigured as an output to a heater and a sensor.

In some embodiments, the controller housing 1304 can also be configuredto facilitate the retention of any attached or coupled connector to oneof the couplers in the harsh operating environment. This is described ingreater detail below, but can include a spring or flexible retainingmechanism that engages a portion of the connector when inserted into acoupler of the controller 1300 to supplement the connector spring thatoften wears out after use or is susceptible to the harsh operatingenvironment, such as high temperatures.

The power switch (not shown) can be any type of switch capable ofselectively providing a portion of the received power to a power load.This can include a contactor, a relay, a solid state device, a knifeswitch, a mercury switch, and a cam switch, by way of example.Additionally, in some embodiments additional circuitry or functionalitycan be included to aid in the switching function. For example, where thepower switch includes a relay, the power control unit or the controllertherein can include an arc reduction relay control circuit or functionfor controlling arcing across contact points of the relay.

While the controller 1300 can be configured for controlling a variety ofoperations of the power control unit including the power switch and thelimiter, in some embodiments, one or both of the power switch and thelimiter can be configured to selectively provide power to the loadindependent of the controller. In such cases, one or both can include aseparate control circuit or processor function.

In some embodiments, the limiter can include a separate processor andmemory and a limiting switch or device for disconnecting the powerprovided by the power control unit to the power load. For example, thelimit switch can be a mechanical relay or solid state relay configuredto open in response to the limit threshold and to close in response to achange in a sensed temperature relative to the limit threshold and upona recycling of the limiter. The limit switch can be coupled before orafter the power switch. The limit threshold can be any known or desiredthreshold of any operating parameter is which a control decision orevent is made. For instance, this could include a temperature, apressure, a humidity, a flow, and a time parameter, by way of example.

The power controller 1300 can be configured to store and operate withone or more user definable threshold limits, such as a high limit andlow threshold limit, or multiple high and low threshold limits ratherthan a single upper or lower limit threshold. In this manner, a varietyof different safety limit functions or operations can be performed bythe single limiter based upon operational or processing needs. This canalso be integrated with the power switch and the controller for thepower switch to provide programmable profiles for a plurality ofoperating processes and functions. The limit thresholds can bepreprogrammed or can be input by a local or remote user interface. Aswill be discussed, in one embodiment, a detachable user interface modulemay be coupled to the control unit that enables a user to input orselect one or more of the controller functions, as well as selecting oneor more limit thresholds. In other embodiments, the limiter can beconfigured to be operative in response to a signal received from thecontroller or from a remote operational system via a communicationfacility or link.

A user interface or user interface module can be configured as describedin more detail below. But can be configured to inter-work with the powercontroller to provide a human machine interface to the controller forreceiving user input including a value of a control system operatingparameter such as the threshold limit. While the user interface can beintegrated into the controller and the controller housing, in someembodiments, the user interface module, the controller housing and thecontroller are configured for releasable coupling of the user interfacemodule from the controller housing and providing a releasable physicaland electrical coupling of the user interface module with the othercomponents of the control system. As noted, the user interface caninclude a display, such as a digital display, one or more user inputmechanisms such as knobs, buttons, by way of example, and one or moredata communication interfaces for communication with a second powercontrol system or an operational system. The user interface module caninclude a security module or function to provide secure access to theuser interface module by a user or via the data communication interface.

The controller 1300 can also be configured with a re-settable parametersuch as an over-temperature value for a control system having a built-inmechanical relay safety limit. The controller 1300 can be configured toprovide this function by controlling the limiter or the limitingfunction in combination with controlling the mechanical relay or otherapproved safety limiting switch. This non-invasive procedure can resetthe temperature value via the user interface and therefore can preventthe requirement for a fuse replacement and/or opening of the powercontroller 1300 which is required by other systems.

Another exemplary parameter re-setting facilitated by the controller1300 and user interface assembly 1302 of various embodiments of thepresent disclosure includes a low temperature alarm (LTA) value limitfunction. A low temperature alarm may be required within a processsystem to provide freeze protection or notification to operators thatprocess conditions are below a limit value where condensation of fluidmaterial may occur, resulting in clogging of media transfer devices(e.g., pipes). The power controller can be configured to permit there-setting of a LTA value via push button keys of the user interface bycontroller software. The programmed inputs being reset in this exampleinclude the lower and upper temperature bounds for the process undercontrol. These limits can be reset by the user without having to shutdown the process under control, thereby eliminating any productionshut-down costs that may be incurred by other prior art control systemsthat require disconnecting the controller to gain access to internalcomponents to replace standard components or to recalibrate or resetcontrol set points. This is an improvement over systems that requiredaccess to internal components such as the resetting of dip switches orthe tweaking of potentiometers for digital or analog controlledcomponents, respectively. The present invention overcomes theselimitations by providing external operator controls to reset controlparameters.

As noted above, in one exemplary implementation of a power control unitor controller 1300 of this disclosure, the power controller 1300 can beconfigured for selectively providing power to a heater as the powerload. In some such embodiments, the power control unit can include asensor input for receiving a temperature signal from a temperaturesensor associated with the heater. Additionally, in some cases, a secondsensor input can be provided for receiving a second temperature signalfrom a second temperature sensor associated with the heater. In thelater case, one or both the controller and limiter can be configured toreceive either one or both of the first temperature signal and thesecond temperature signal.

For example, in one embodiment, both the controller and limiter receiveboth temperature signals. The controller and the limiter can bothoperate on one or both signals, with one of them being a backup orsafety check. In other cases, the controller and limiter can communicateone or both signals to the other component as a feedback or comparisoninput into the controlling functions. In this manner, both the limiterand the controller have redundant inputs for one or more temperaturesignals, thereby providing increased operations of the power controlunit. In other embodiments, more than two temperature or other signalscan also be received and utilized in a similar manner for controller andlimiter operations. For example, one or both of the temperature signalsfrom the temperature sensors associated with a heater can be utilized byboth the controller and the limiter to ensure proper temperature controlof the operation as well as to ensure the safety of the process, theheater, the power control unit and system.

In other embodiments, the controller 1300 can include a low temperaturealarm module (not shown) configured for receiving a low temperaturethreshold as defined by a user or an operational system. A temperaturefrom a temperature sensor is provided to the controller as discussedabove, and the controller can generate an alarm in response to thereceived measured temperature being less than the predefined lowtemperature threshold. This can be helpful in trouble shooting aprocessing system since low temperature can often significantly impactthe quality of the production process.

As noted, the controller 1300 can include a processor and a memoryand/or computer readable medium having computer executable instructionsfor performing a controlling function of the power switch, the limiter,or other power controller functions. For example, the controller 1300with the processor, memory and computer executable instructions can beconfigured to generate the power switch control signal as a function ofa control algorithm or function, such as, a proportional, integral,derivative (PID) function, an adaptive PID function, a proportionalfunction, a proportional/integral function, a proportional, integral,and two derivative control (PIDD) function, a feed forward function, anda feedback function, by way of example.

In some embodiments, a power controller 1300 can be a power controllerfor a thermal processing system and include a controller housing, aninput power interface for receiving power from a power source and anoutput power interface for providing power to a power load. A powerswitch is disposed within the controller housing for selectivelyproviding, at least a portion of, the received power to the power load.A temperature sensor interface is configured for receiving a temperaturesignal from a temperature sensor. A safety limiter is disposed withinthe controller housing and includes a plurality of threshold temperaturelimits. The limiter is configured for providing a safety limit switchingfunction in response to two or more of the threshold temperature limitsand the received temperature signal. A controller is disposed within thecontroller housing and is configured for controlling the selectiveproviding of power by the power switch.

In some embodiments, a method of providing power to a heating elementincludes receiving power from a power source, sensing a temperatureassociated with the heating element, and selectively providing, at leasta portion of, the received power to the heating element in response tothe sensed temperature. The method also includes comparing the sensedtemperature to a plurality of safety thresholds, and limiting theselective providing of the received power to the heating element inresponse to the comparing. As noted above, the method can includereceiving two or more user defined safety thresholds. In such cases, thecomparing can include comparing the two or more user defined safetythresholds for providing the limiting function.

As noted above, in some embodiments, the power control system having apower switch with a relay can include a no-arc relay control circuit orfunction also within the controller housing. The no-arc relay controlcircuit can include an auto-clean module with a relay contact cyclecounter for counting the number of relay cycles. The auto-clean modulecan suppress an operation of the no-arc control circuit as a function ofthe number of relay cycles to provide an arc across the relay. While thenumber of cycles can be any number, in one embodiment the auto cleanmodule enables the arc across the relay in about every 20,000 relaycycles to provide for cleaning of the contacts. In another embodiment,the auto clean module can enable the arc across the relay during initialpowering of the system. The no-arc relay control circuit can alsosuppress arcing upon the opening of the relay but allows for arcingduring the closing of the relay. In some embodiments, the no-arc relaycontrol includes a solid state switching device coupled in parallel withthe relay.

In some embodiments, a no-arc circuit can be incorporated into thethermal control system by having the contacts of a relay type powerswitch in parallel with a solid state switching device. Such a no-arccircuit and method provides for the extended life of the relay. Forinstance, most manufacturers rate the life cycle of relays at 100,000cycles. However, a no-arc circuit having a solid state switching devicein parallel with the relay contacts has been demonstrated as extendingthe life of the relay to greater than 3,000,000 cycles, a thirty-foldimprovement. In addition, in some embodiments an “auto clean” module andprotocol includes a contact cycle counter for counting the number ofrelay contacts and provides for the allowed arcing at predeterminedcycle counts to allow for self-cleaning of the relay contacts. Forinstance, in one embodiment the cycles are counted and the relay isallowed to arc approximately every 20,000 cycles. As such, the “no-arc”suppression circuit is eliminated or bi-passed to allow for the naturalarcing to occur across the contacts of the relay. In another embodiment,the allowed cleaning arc can be a manicured or conditioned arc, forexample, of a particular level or duration, or can be only duringopening or closing of the contacts. The controlled arcing provides forthe removal of oxidation on the relay contacts that may build up due tothe elimination of natural arcing. This is especially applicable in lowcurrent applications

In another embodiment, a no-arc circuit can minimize or eliminatecontact damage from arcing when the relay contacts are opened. Thiscircuit allows for minimal arcing to occur during the making of thecontacts thereby allowing cleaning action to remove carbonization andcontamination material from the contract surface. Otherwise, the circuiteliminates arcing during the opening of the relay contacts as arcingduring opening is more damaging to the relay contacts. In otherembodiments, a circuit or function can be configured to eliminate arcingcompletely. In one or more embodiments of the invention, an inductivekick from the switched device is also provided to its parallel solidstate device to eliminate the arc during opening of the contacts. Theno-arc circuit can also provide timing for the on (conducting) durationof the solid state device to minimize the on-time conducting duration ofthe solid state device, that can produces an embodiment that requires noheat sinking of the solid state device.

Power Controller User Interface

In some embodiments, a user interface assembly for a power controllerhas a housing adapted for mechanically coupling to a controller housingof the power controller and a display visible on an outer surface of thehousing for providing a visual presentation to a user. The userinterface housing can be a compact case for enclosing the user interfaceassembly. The housing can include one or more engaging features, such aslocking tabs, clips, edges, flanges, by way of example, for mechanicallycoupling the user interface housing to a receiving portion of thecontroller housing. The housing can also be dimensioned to be anintegrated unit with the controller housing upon the mechanical couplingof the housing to the controller housing.

The display can include any type of display capability such as LEDs,LCDs, or a full graphical, digital or analog display. The display can beconfigured for presenting a plurality of parameter values to the user inresponse to the user manipulating the user input mechanism. A user inputmechanism is configured for receiving an input from the user and can beconfigured for controlling an operation of the power controller whencoupled to the user interface assembly. The user input mechanism can begenerally configured to receive an input or instruction from a user andto communicate the received input or instruction to the controller, alimiter, or any other component or function of the power controller. Theuser input mechanism can include any type of input including one or morebuttons, knobs, keys, voice inputs, touch pads, joysticks, a scroll, aball, by way of example.

A user interface circuit is disposed within the housing and is coupledto the display. The user interface circuit can coordinate betweendisplaying one or more characteristics or messages for the user,receiving the inputs from the user input mechanisms, and communicatingthe information to and from one or more components of the powercontroller. The user interface circuit can include a security module orfunction that is configured to require the receiving of a security codesuch as a password by a user prior to enabling the user interface orprior to receiving a user input or to communicating a user input toanother power controller component. The security code is typically apredetermined code. The user interface circuit can be configured todisplay a prompt to the user on the display, receive an input from theuser input mechanism, and compare the user input to a predeterminedsecurity code.

The user interface assembly can include a connector adapted forelectrically connecting the user interface circuit to an electricalconnector associated with the power controller. This connector caninclude a mechanical coupling as well as an electrical coupling. In someembodiments, this can be a physical coupling or a wireless couplingusing one or more communication frequencies or wavelengths andassociated wireless interfaces.

The user interface assembly can also include a visual indicatorconfigured for receiving a visual signal generated by a controller orthe controller housing upon mechanical coupling of the housing to thecontroller housing. This can include a relaying the received visualsignal to a visible portion of the user interface assembly for providinga visual indication of the received visual signal. For example, a powercontroller can include one or more LEDs that may be indicative of astatus or operation of the controller. Rather than duplicating the LEDsthat may be located on a portion of the controller housing to which theuser interface assembly is attached, the user interface assembly can beconfigured to include one or more passive light conducting channels suchas a plastic or fiber optic material such that the received light fromthe LEDs are repeated to an external portion of the user interfaceassembly without requiring the cost of an active circuit or function. Ofcourse, in other embodiments, the user interface assembly can include anactive circuit or function for also providing power control system orcomponent status or operations.

The user interface assembly can also include a data communicationinterface coupled to the user interface circuit for communicating with asecondary system such as another user interface assembly, anothercontroller, or an operations system. The data communication interfacecan be a wired interface including a coupler or connector for mechanicaland electrical coupling to a data communication facility. In otherembodiments, the data communication interface can be a wirelessinterface including a wireless transceiver. The user interface circuitcan include a system identification module for generating a systemidentification signal over the data communication interface to providefor identifying the particular control unit from among a plurality ofcontrol units in a communication facility or in an operationalenvironment. This can be automatically provided upon connection to thecommunication facility or can be in response to a ping or a request viaa data communication protocol.

In some embodiments, the user interface assembly can also be configuredwith a visual or audio generator or indicator that provides a visualand/or audio identification or indicator in response to the datacommunication interface receiving a power control system identificationrequest signal from another system. This capability can enable a user toping all or particular power control systems and/or user interfaceassemblies to help to identify one within a complex operationalimplementation that may require service or maintenance.

In some embodiments, a power control system has a control unit with acontroller housing, a power switch disposed within the controllerhousing for selectively providing power from a power supply to a powerload and a controller disposed within the controller housing that isconfigured for controlling the selective providing by the power switch,and a user interface connector. A limit switch can be disposed withinthe controller housing and can be configured for providing a limitswitching for terminating the providing of power by the control unit tothe power load in response to a threshold limit. The user interfaceassembly, as described above, can be coupled to this the powercontroller housing. The user interface assembly can be configured toreceive one or more threshold limits, power switch, or controllerparameters or controls from the user. In some embodiments, the controlunit can be configured for selectively providing power from a powersupply to a power load independent of the user interface assembly beingcoupled to the control unit. In other embodiments, one or both of thecontroller and the limiter can be independently configured for operatingindependent of the user interface assembly being coupled to thecontroller housing and the controller. In light of above description,one exemplary embodiment of a power controller 2710 including a powerswitch 2720 and a safety limiter 2730 enclosed within the housing 2740is showen in FIG. 27.

Additionally, in some embodiments, a cover can be adapted for couplingto the controller housing in the absence of the user interface housingbeing coupled to the controller housing.

According to still another aspect of the invention, a method foroperating a power controller includes connecting an input of the powercontroller to a power source, connecting a power load to an output ofthe power controller and coupling a user interface assembly to a housingof the power controller. The power controller housing encloses a powerswitch, a limiter, and a controller. The method also includes inputtinga limit threshold into the user interface assembly. The user interfaceassembly is configured to transmit the limit threshold to the controllerfor controlling the limiter.

The user interface assembly can be configured for transmitting one ormore limit thresholds or one or more replacement limit threshold fromthe user interface assembly as input by a user or as received via a datacommunication to the controller. The controller and/or the limiter canreceive the transmitted thresholds for controller the providing of powerin response thereto.

By way of example, in one operation of the user interface assembly ormodule, the user can input or select a control set point via usermanipulation of push button keys or via controller-specific softwarecommands that allow user adjustment of set point parameter values.Adjustments to set points can be provided during operation of thecontroller via the user interface assembly without requiring placing thecontroller in an off-line mode. In this manner, process changes can beimplemented for different temperatures, alternative media, changes tosensor or sensor types, and for process improvements during processingor operations.

In some embodiments, a user interface assembly for a power controllerhas a housing adapted for mechanically coupling to a controller housingof the power controller in a releasable manner, a display visible on anouter surface of the housing for providing a visual presentation to auser, and a user input mechanism for receiving an input from the user.The mechanical coupling can be by a variety of different mechanicalcoupling mechanisms including tabs, clips, flanges, cam surfaces,magnets, by way of example.

A user interface circuit is disposed within the housing and coupled tothe display and the user input mechanism for controlling an operationthe power controller when coupled to the user interface assembly. Aconnector is coupled to the user interface circuit and is adapted forelectrically connecting the user interface circuit to an electricalconnector associated with the power controller upon the mechanicalcoupling of the housing to the controller housing and electricallydisconnecting upon mechanical decoupling of the housing from thecontroller housing.

Additionally, the user interface assembly can include one or moreconnectors or interfaces for coupling to an external communicationfacility or connector associated therewith. The communication interfacecan provide for communication with operational systems or other userinterface assemblies or controllers within the operating environment ofthe power control system.

In some embodiments, the housing, connector, and user interface circuitare all configured for releasably coupling of the user interfaceassembly to a controller housing and controller on a hot pluggablebasis, e.g., without requiring the controller to be placed in anoff-line or idle mode. For example, a controller can have an inactivemode when power is not being provided to a load and an active mode whenpower is being provided. In these cases, in some embodiments, the userinterface module can be configured to be coupled or uncoupled from thecontroller during the active mode and/or the inactive mode. This hassignificant operational advantages over the previous controllers anduser interfaces by enabling a user to change or re-program a controllerwithout interrupting a current process.

As the user interface assembly is adapted for releasable coupling to thecontroller housing, the user interface assembly can be utilized forcoupling to more than one controller housing and therefore to more thanone controller at separate instances. In this manner, a single userinterface assembly can be utilized for individually interfacing aplurality of controllers implemented in an operating application. Insome embodiments, a cover can be provided to take the place of a userinterface when the user interface module is not attached to thecontroller. The cover can provide for protecting or sealing thecontroller housing, protecting wiring connections, or providing improvedlooks of the controller. Additionally, the cover can be configured toinclude an active or passive visual indicator or other features orfunctions that may be desired of a less than full featured userinterface module.

In some embodiments, a power control system includes a control unithaving a controller housing, a power switch disposed within thecontroller housing for selectively providing power from a power supplyto a power load. A controller is disposed within the controller housingand is configured for controlling the selective providing of power bythe power switch. The controller includes a user interface connector.The control unit can also include a limiter disposed within thecontroller housing configured for providing a limit switching functionin response to a threshold limit and wherein the user interface assemblyis configured for receiving user input including a value of thethreshold limit and communicating the received threshold limit to thelimiter.

In some embodiments, the invention can include a method of controlling apower controller containing a power switch and a controller configuredfor selectively providing power to a power load includes releasablycoupling a user interface module to a controller housing containing thepower switch and the controller and displaying a controller parameter onthe user interface module. The method also includes receiving a userinput including a user definable parameter value via the user interfacemodule and communicating the user definable parameter value from theuser interface module to the controller. The method further includesdecoupling the user interface module from the controller housing andcontrolling a function of the controller in response to the userdefinable parameter value.

In other embodiments, a method for operating a power controller providespower to a power load wherein the method includes connecting an input ofthe power controller to a power source, connecting an output of thepower controller to the power load, and coupling a releasable userinterface assembly to a body of the power controller. The powercontroller body encloses a power switch, a limiter, and a controller.The method also includes inputting a controller parameter value into thereleasable user interface assembly. The releasable user interfaceassembly communicates the controller parameter value to the at least oneof the controller and the limiter. The method further includes providingat least a portion of the power received at the input from the powersource to the power load connected to the output in response to theinput controller parameter value and decoupling the releasable userinterface assembly from the power controller body.

The method can also include re-coupling the releasable user interfaceassembly to the power controller body, inputting a replacement parametervalue, such as a safety threshold value for the limiter or/and a powerswitch setting, into the releasable user interface, communicating thereplacement controller parameter value from the releasable userinterface assembly to at least one of the controller and the limiter,and controlling at least one of the controller and the limiter forselectively providing power to the power load in response to thereplacement parameter value. Additionally, the method can includedecoupling the releasable user interface following the inputting areplacement controller parameter value, the decoupling being during thecontrolling of the selective providing of power to the power load.

As noted above, there can be more than one power controller adapted forreceiving the same user interface assembly. In such cases, a first powercontroller having a first power controller body and a second powercontroller connecting a second power load to an output of the secondpower controller are each releasably coupable to the same user interfaceassembly for controlling or receiving an input from a user.

Referring again to FIG. 13, the user interface module or assembly 1302includes a digital display 1310 for indicating an operation of thesystem which can be configured to display diagnostic information as wellas set point information. A data communication interface 1312 isprovided for communication with secondary system. The data communicationinterface 1312 can be enabled for communicating with multiple othersystems, or with a remote controller or control system.

The power control system can include an integrated limiter that isprogrammably set by front panel controls. When the programming mode isenabled, the controller initiates the program routine and steps theoperator through the programming process. The controller 1300 caninclude a user interface assembly 1302 including a scrolling (e.g.,scroll increment 1314, scroll decrement 1316) for advancing throughtemperature set point choices displayed to the operator on display. Theembodiment illustrated in FIG. 13 is a three digit display 1310 but, inother embodiments, can be a display of any number of digits as requiredby the process application and the parameter limit being programmed. Insome embodiments, the user interface 1302 can include an on/off control1318 for activating the control display.

In another embodiment, e.g., for applications not requiring frequentresetting of thermal set points, the programming module can be used forthe initial configuration and thereafter used as a portable programmingunit. In this embodiment, a cover 1702 is installed on the controllerhousing 1304 as shown in FIG. 17 after initial programming set-up.Additionally, in this manner the same user interface assembly 1302 canbe used for more than one controller 1300.

In another embodiment, multiple power control systems configured withmultiple user interface assemblies can be deployed in a daisy chainfashion using the communications interfaces 1312. In this configuration,a standard communications interface, such as EIA 485, may be used andthe monitoring and reprogramming of individual thermal control systemscan be programmed from a central operator console position.

Referring now to FIG. 15, the user interface module or assembly 1302 fora power controller includes the user interface housing 1303 that isseparate from the controller housing 1304 and that is detachable fromthe controller housing 1304 and is hot pluggable with the controller1300. As shown, the user interface housing 1303 includes a display anduser input mechanisms as well as supporting electronics (not shown) andconnectors for coupling communication wiring connectors. The userinterface housing can include one or more tabs 1502 or similarlyfunctional physical coupling features that are configured for physicallyinterlocking the user interface housing to the controller housing 1304.

As shown further in FIG. 16, the user interface assembly 1302 and userinterface housing 1303 includes, in this exemplary embodiment, threecoupling tabs 1502 configured to physically couple to the controllerhousing 1304. It should be understood to those skilled in the art thatthe number of coupling tabs 502 may be more or less than three.Additionally, other types of coupling fasteners or methods can also beutilized to releasably couple the user interface housing 1303 to thecontroller housing 1304.

As noted above, the user interface assembly 1302 typically includeselectronics to support the display and user input mechanismfunctionality. In FIG. 16, one example of such electronics includes aprinted circuit board 1504 that hosts the user interface controlcircuitry and programming electronics. A human machine interface (HMI)or user interface 1602 is positioned on the under side of the userinterface module/assembly 1302 for electrically coupling the userinterface and the electronics therein to the controller housing 1304. Asshown, the circuit board 1504 can be protected with a protective shield1505 that can include an EMI shield. This electrical mating can includecoupling of power and communications between the user interface and thecontroller.

As shown in FIG. 16, the HMI/Controller interface 1602 includes aconnector 1604 having one or more conductors 1606 configured to matewith a mating electrical connector of the controller base. In otherembodiments, the user interface assembly 1302 may include fewer orgreater number of connectors 1602 and/or conductors 1606 or may includea wireless or optical communication component or capability.

A user interface assembly 1302 illustrated in one embodiment in FIG. 18can include a display for indicating an operation of the system. Theuser interface module can also include a data communication interface1312 for communication with a remote control system.

In some cases, a cover 1702 as shown in FIG. 17 can be provided to mountto the housing to replace the user interface module when the userinterface module is not attached to the housing. FIG. 17 alsoillustrates an interface connector 1704 on the controller 1300 that isconfigured for receiving a mating connector of a user interface whencoupled to the controller 1300 as described above and in FIGS. 13-16.

Controller Housing with Connector Retention

In some embodiments, a housing assembly has a case defining an openingand a securing portion positioned proximate to the opening. A coupler ispositioned within the opening and configured for coupling to aconnector. The case can include, in some embodiments, a biasing cavitysuch that the securing portion is defined by a portion of the casebetween the biasing cavity and the opening. This can also include aflexible portion of the case configured to flex away from the couplerupon coupling of the connector with the coupler and to provide a biasingforce against the connector portion when the connector is coupled withthe coupler. The case and the securing portion thereof are configuredfor securing a portion of the connector when coupled with the coupler.

The case can be configured as a single unitary case or housing body orcan have one or more case housings. In one embodiment, the case includesa first case housing and a second case housing such that the first casehousing and the second case housing can be coupled together tosubstantially form the case. The opening can be defined by a portion ofthe first case housing and a portion of the second case housing. Inother embodiments, the opening can be substantially defined by the firstcase housing and the securing portion can be defined by a surface edgeof the second case housing. The securing portion can include a flange orsimilar surface or structure disposed about a portion of the openingsuch that it can be compressively biased against a portion of theconnector such as a flexible locking lever of the connector.

As is well known, the one or more cases and/or housings can be made ofmetal or a thermoplastic material, such as a polycarbonate. The case canbe configured for enclosing any electrical component and can include, ina power controller application of the invention, a power switch and acontroller that selectively provide power to a power load, such as aheater. In such embodiments, two or more openings and securing portionscan be provided for separately securing more than one connector. Forexample, this can include an input power connector for receiving powerfrom a power source and an output power connector for providing power tothe power load. Additionally, in some embodiments, the case can beconfigured for enclosing a safety limiter and the one or more connectorscan, not only provide input or output power but can also provide one ormore sensor signals, such as temperature sensor signals from atemperature sensor associated with the power load.

In some embodiments, as noted above a first coupler can be configuredfor receiving power from a power source and a second coupler can beconfigured for providing power to a power load. In such cases, the firstcoupler and the second coupler are color coded to indicate one as aninput coupler and one as an output coupler. For example, the firstcoupler can be colored black and the second coupler can be colored whitefor easy user identification. Of course other color or colordesignations are also considered to be within the present disclosure.

In some applications, female/male or male/female standard couplers andconnectors can be used rather than customized versions thereof. Forinstance, in some embodiments, the coupler and/or connector can becompatible with an industry-wide connector such as a Molex® Minifit-Jr.®connector (Molex® and Minifit-Jr.® are registered trademarks of Molex,Inc.) as shown, by way of example, in FIG. 24. This connector 2400includes a body 2402, a plurality of position connectors 2404 eachhaving an electrical conductor. A connector locking arm 2406 with asecuring hook 2408 is configured for engaging an exterior portion of thecompatible coupler (not shown in FIG. 24). In this case, the securingportion of the case or housing can include having a cam-like edge orsimilar feature to allow the connector locking arm 2406 to flex thesecuring portion during connection and then to provide a continuing biasto the connector locking arm 2406 to secure the connector locking arm2406 in a locked or hooked position with the coupler, e.g., such thatthe securing hook 2408 of the connector locking arm 2406 is biaseddownward.

In some embodiments, a power control system has a power switch forselectively providing at least a portion of power received from a powersource to a power load in response to a controller. The coupler isconfigured for coupling to an external connector and a housing forenclosing the controller and the power switch, the housing defining acoupler opening for external access to the coupler and having a biasingportion located proximate to the coupler opening for providing a biasingforce to an engaging portion of a connector when the connector iscoupled with the coupler. The biasing portion is configured to securethe connector in the coupled position with the coupler.

According to still another aspect of the invention, a method ofoperating a power controller having a housing enclosing a power switchfor receiving power from a power source and selectively providing atleast a portion of the received power to a power load includes insertinga connector into an opening defined by the housing enclosing the powerswitch and the controller, flexing a securing portion of the housingproximate to the opening during the inserting of the connector into theopening, and coupling the connector to a coupler positioned within theopening. The method also includes securing the securing portion of thehousing against a locking portion of the connector following coupling ofthe connector to the coupler. The method can include compressing thelocking portion of the connector, flexing the securing portion of thehousing upon the compressing, withdrawing the connector from theopening, and decoupling the connector from the coupler.

Another embodiment of the present invention can provide for aninterlocking compressive force of the physical design of the connectorcavities 706 above the couplers 1306. A male connector and femalecoupler according to one exemplary embodiment of the invention areillustrated in FIG. 19. However, it should be understood that othercombinations, matings and coupling arrangements are also possible.Typically each includes a corresponding number of conductor positions1901, each providing a mating electrical connectivity upon coupling ofthe connector to the coupler. The male connector 1902 has a connectorlocking arm 1904 that slideably lifts over a securing or locking tab1906 of the coupler 1908 to secure the connector to the coupler 1908.When inserted into the coupler 1908, the connector lever arm 1904 slidesover a ramp of the securing tab 1906 with the tab edge of the lockinglever arm 1904 latching over the end of the securing tab 1906 to securethe connection. In FIG. 19, a 10-position connector 1902 and coupler1908 are illustrated. However, it should be noted other quantities ofpositions 1901 in the connector 1902 and coupler 1908 are also withinthe scope of the present invention. In one embodiment, the coupler is an8-position coupler 1908 adapted to receive an 8-position connector 1902.

Referring now to FIG. 20, to prevent premature disconnection therebylengthening the cycle life of the number of such connections anddisconnections, a retaining slot cam-like surface 2002 can provide acompressive force on the male connector locking arm as illustrated inone embodiment in FIG. 20 and a second compressive cam-surface 2102embodiment in FIG. 21. Each embodiment of FIGS. 20 and 21 include abiasing cavity, 2006 and 2106, a biasing portion or element 2004 and2104, and a retaining compression cam surface 2002 and 2102,respectively for retaining a coupler 1908.

Referring now to FIG. 23, one exemplary embodiment of a power controller2300 has two connectors 2302A and 2302B coupled with two couplers (notshown in FIG. 23) and retained by securing portions 2004A and 2004B,respectively, of the housing 1302.

As another example, where the case can include two housing portions,FIGS. 25 and 26 show a disconnected two housing case as shown in FIG.23, but with a single connector 2302. FIG. 25 illustrates the connector2302 coupled with the coupler 1908 such that the connector locking arm2406 has the securing hook 2408 engaged with the securing or locking tab1906 of the coupler 1908. FIG. 26 illustrates the operation of thesecuring portion of the connector retainer housing. As shown, theconnector 2302 is still coupled to the coupler 1908 with the connectorlocking arm 2406 having the securing hook 2408 engaged with the securingtab 1906. However, as shown the housing 1302 includes the biasing cavity2006 that flexed to allow the connector locking arm 2406 to pass duringcoupling of the connector 2302 with the coupler 1908. The retaining camsurface 2002 continues to bias the connector locking arm 2406 with adownward force after coupling to secure the connector locking arm 2406and the securing hook 2408 against and behind the locking tab 1906 ofthe coupler 1908. In this manner, even after the connector locking arm2406 has lost some of its initial bias or has lost some of its flex, thesecuring portion of the housing 1302 ensures that the connector lockingarm 2406 stays coupled to the coupler 1908 unless user interactionforces the securing portion to flex away from the connector locking arm2406 and the coupler 1908.

Power Controller Processing System and Environment

Referring now to FIG. 22, a computer/processing system for one or moreexemplary embodiments of a controller, limiter, and/or user interfacemodule of the present disclosure can include a computer or processingsystem 2200 having a computer 2202 that comprises at least one highspeed processing unit (CPU) 2204, in conjunction with a memory system2206 interconnected with at least one bus structure 2208, an inputdevice 2210, and an output device 2212. These elements areinterconnected by at least one bus structure 2208.

The illustrated CPU 2204 is of familiar design and includes anarithmetic logic unit (ALU) 2214 for performing computations, acollection of registers 2216 for temporary storage of data andinstructions, and a control unit 2218 for controlling operation of thesystem 2200. Any of a variety of processor, including at least thosefrom Digital Equipment, Sun, MIPS, Freescale (Motorola), NEC, Intel,Cyrix, AMD, HP, and Nexgen, is equally preferred for the CPU 2204. Theillustrated embodiment of the invention operates on an operating systemdesigned to be portable to any of these processing platforms.

The memory system 2206 generally includes high-speed main memory 2220 inthe form of a medium such as random access memory (RAM) and read onlymemory (ROM) semiconductor devices, and secondary storage 2222 in theform of long term storage mediums such as floppy disks, hard disks,tape, CD-ROM, flash memory, etc. and other devices that store data usingelectrical, magnetic, optical or other recording media. The main memory2220 also can include video display memory for displaying images througha display device. Those skilled in the art will recognize that thememory system 2206 can comprise a variety of alternative componentshaving a variety of storage capacities.

The input device 2210 and output device 2212 are also familiar and canbe implemented associated with the local and remote user interfaces aswell as a controller, remote operational system and operations system,by way of example. The input device 2210 can comprise a keyboard, amouse, a physical transducer (e.g. a microphone), etc. and isinterconnected to the computer 2202 via an input interface 2224. Theoutput device 2212 can comprise a display, a printer, a transducer (e.g.a speaker), etc, and be interconnected to the computer 2202 via anoutput interface 2226. Some devices, such as a network adapter or amodem, can be used as input and/or output devices.

As is familiar to those skilled in the art, the computer system 2200further includes an operating system and at least one applicationprogram. The operating system is the set of software which controls thecomputer system's operation and the allocation of resources. Theapplication program is the set of software that performs a task desiredby the user, using computer resources made available through theoperating system. Both are resident in the illustrated memory system2206. As known to those skilled in the art, some of the methods,processes, and/or functions described herein can be implemented assoftware and stored on various types of computer readable medium ascomputer executable instructions. In various embodiments of the powercontrol system described by example herein, the controller can include arobust operating and application program having the computer executableinstructions for controlling the controller and the controlled devices.Additionally, one or more of the local and remote user interfaces,operations system and remote operations system can include, among otherapplication software programs with computer executable instructions, athin client application for communicating and interactively operatingwith one or more controllers as described above by way of example.

In accordance with the practices of persons skilled in the art ofcomputer programming, the present invention is described below withreference to symbolic representations of operations that are performedby the computer system 2200. Such operations are sometimes referred toas being computer-executed. It will be appreciated that the operationswhich are symbolically represented include the manipulation by the CPU2204 of electrical signals representing data bits and the maintenance ofdata bits at memory locations in the memory system 2206, as well asother processing of signals. The memory locations where data bits aremaintained are physical locations that have particular electrical,magnetic, or optical properties corresponding to the data bits. Theinvention can be implemented in a program or programs, comprising aseries of instructions stored on a computer-readable medium. Thecomputer-readable medium can be any of the devices, or a combination ofthe devices, described above in connection with the memory system 2206.

It should be understood to those skilled in the art, that someembodiments of systems or components described herein may have more orfewer computer processing system components and still be within thescope of the present invention.

When describing elements or features of the present invention orembodiments thereof, the articles “a”, “an”, “the”, and “said” areintended to mean that there are one or more of the elements or features.The terms “comprising”, “including”, and “having” are intended to beinclusive and mean that there may be additional elements or featuresbeyond those specifically described.

Those skilled in the art will recognize that various changes can be madeto the exemplary embodiments and implementations described above withoutdeparting from the scope of the invention. Accordingly, all mattercontained in the above description or shown in the accompanying drawingsshould be interpreted as illustrative and not in a limiting sense.

It is further to be understood that the steps described herein are notto be construed as necessarily requiring their performance in theparticular order discussed or illustrated. It is also to be understoodthat additional or alternative steps may be employed.

1. A housing assembly comprising: a case defining an opening and asecuring portion positioned proximate to the opening; and a couplerpositioned within the opening and configured for coupling to aconnector, wherein the case and securing portion are configured forsecuring a portion of the connector when coupled with the couplerwherein the case defines a biasing cavity and wherein the securingportion is defined by the biasing cavity and the opening, the securingportion biasing a locking lever of the connector into a locked position;wherein the securing portion is an integral portion of the case thatextends between the biasing cavity and the opening; wherein the securingportion includes a flexible portion of the case configured to flex awayfrom the coupler upon coupling of the connector with the coupler and toprovide a biasing force against the connector portion when the connectoris coupled with the coupler.
 2. A housing assembly comprising: a casedefining an opening and a securing portion positioned proximate to theopening; and a coupler positioned within the opening and configured forcoupling to a connector, wherein the case and securing portion areconfigured for securing a portion of the connector when coupled with thecoupler wherein the case defines a biasing cavity and wherein thesecuring portion is defined by the biasing cavity and the opening, thesecuring portion biasing a locking lever of the connector into a lockedposition; wherein the securing portion is an integral portion of thecase that extends between the biasing cavity and the opening; whereinthe case includes a first case housing and a second case housing, thefirst case housing and the second case housing are coupled together tosubstantially form the case, and the opening is defined by a portion ofthe first case housing and a portion of the second case housing.
 3. Theassembly of claim 2 wherein the coupler is positioned with the openingdefined by the first case housing and wherein the securing portion isdefined by a surface edge of the second case housing.
 4. A housingassembly comprising: a case defining an opening and a securing portionpositioned proximate to the opening: and a coupler positioned within theopening and configured for coupling to a connector, wherein the case andsecuring portion are configured for securing a portion of the connectorwhen coupled with the coupler wherein the case defines a biasing cavityand wherein the securing portion is defined by the biasing cavity andthe opening, the securing portion biasing a locking lever of theconnector into a locked position; wherein the securing portion is anintegral portion of the case that extends between the biasing cavity andthe opening; wherein the securing portion includes a flange disposedabout a portion of the opening, the flange configured for compressivelybiasing the locking lever of the connector in the locked position. 5.The assembly of claim 1 wherein the case comprises a thermoplasticmaterial.
 6. The assembly of claim 5 wherein the thermoplastic materialof the case is a polycarbonate.
 7. The assembly of claim 1 wherein thecase is configured for enclosing a power switch and a controller forselectively providing power to a power load and wherein the coupler isconfigured for at least one of receiving power from a power source andproviding power to the power load.
 8. The assembly of claim 7 whereinthe case is configured for enclosing a safety limiter and wherein thecoupler is configured for receiving at least one temperature signal fromat least one temperature sensor associated with the power load.
 9. Theassembly of claim 1 wherein the opening is a first opening and thecoupler is a first coupler, and wherein the case defines a secondopening, further comprising a second coupler positioned within thesecond opening and configured for coupling to a second connector,wherein the case defines a second securing portion positioned proximateto the second opening and configured for securing a portion of thesecond connector when coupled with the second coupler.
 10. The assemblyof claim 9 wherein the case defines a second biasing cavity and whereinthe second securing portion is defined by the second biasing cavity andthe second opening.
 11. The assembly of claim 9 wherein the firstcoupler is configured for receiving power from a power source via thefirst connector and wherein the second coupler is configured forproviding power to a power load via the second connector.
 12. The systemof claim 9 wherein the first coupler and the second coupler are colorcoded to indicate one as an input coupler and one as an output coupler.13. The system of claim 12 wherein the first coupler is colored blackand is configured as an input from a power source and the second coupleris colored white and is configured as an output to a heater and asensor.
 14. The assembly of claim 1 wherein the coupler is compatiblewith a Molex Minifit-Jr.® connector.
 15. The assembly of claim 1 whereinthe securing portion includes a flexible cam-like edge providing asecuring force to a the locking lever of the coupled connector.
 16. Theassembly of claim 1 wherein the coupler is a female oriented coupleradapted for receiving a male oriented connector.
 17. A power controlsystem having a power switch for selectively providing at least aportion of power received from a power source to a power load inresponse to a controller, the system comprising: a coupler for couplingto an external connector; and a housing enclosing the controller and thepower switch, the housing defining a coupler opening for external accessto the coupler and having a biasing portion located proximate to thecoupler opening providing a biasing force to an engaging portion of aconnector when the connector is coupled with the coupler, the biasingportion configured to secure the connector in the coupled position withthe coupler wherein the power control system includes a safety limitercontrolling the providing of power to the power load as a function of athreshold limit and wherein the housing encloses the limiter along withthe controller and the power switch; wherein the housing includes aflexible cam-like edge providing the biasing force to a connecting leverarm of the coupled connector urging the lever arm into a lockedposition; wherein the flexible cam-like edge is defined by a biasingcavity and the coupler opening and is configured to be in a flexedposition and to engage the engaging portion of the connector when theconnector is coupled with the coupler.
 18. The system of claim 17wherein the biasing portion includes a flexible portion configured toflex away from the coupler during the coupling of the connector with thecoupler and to provide the biasing force against the engaging portion ofthe connector following coupling of the connector with the coupler. 19.The system of claim 17 wherein the housing defines a biasing cavity,wherein the biasing portion is defined by a portion of the housingpositioned between the coupler opening and the biasing cavity.
 20. Thesystem of claim 17 wherein the coupler is a first coupler configured forreceiving power from a power source, further comprising a second couplerconfigured for providing power to the power load, wherein the housing isconfigured with a second coupler opening for external access to thesecond coupler and having a second biasing portion located proximate tothe second coupler opening for providing a second biasing force to anengaging portion of a second connector when the second connector iscoupled with the second coupler, the second biasing portion configuredto secure the second connector in the coupled position with the secondcoupler.
 21. A method of operating a power controller having a housingenclosing a power switch for receiving power from a power source andselectively providing at least a portion of the received power to apower load, the method comprising: inserting a connector into an openingdefined by the housing enclosing the power switch and the controller;flexing a securing portion of the housing defined by a biasing cavityand the opening during the inserting of the connector into the opening;coupling the connector to a coupler positioned within the opening; andsecuring the securing portion of the housing against a locking portionof the connector following coupling of the connector to the couplerthereby retaining the locking portion in a locked position; wherein thesecuring portion is an integral portion of the case that extends betweenthe biasing cavity and the opening.
 22. The method of claim 21 whereinsecuring portion includes biasing the securing portion against thelocking portion of the connector.
 23. The method of claim 21 wherein thecoupler is configured for at least one of receiving power from a powersource coupled to the connector and providing power to a power loadcoupled to the connector.
 24. The method of claim 21 wherein the housingencloses a safety limit and wherein the coupler is configured forreceiving a temperature signal from a temperature signal associated withthe power load.
 25. The method of claim 21, further comprisingcompressing the locking portion of the connector; flexing the securingportion of the housing upon the compressing; withdrawing the connectorfrom the opening; and decoupling the connector from the coupler.
 26. Themethod of claim 21 wherein the connector is a first connector, thecoupler is a first coupler, further comprising: inserting a secondconnector into a second opening defined by the housing; flexing a secondsecuring portion of the housing proximate to the second opening duringthe inserting of the second connector into the second opening; couplingthe second connector to a second coupler positioned within the secondopening; and securing the second securing portion of the housing againsta locking portion of the second connector following coupling of thesecond connector to the second coupler.
 27. The method of claim 26,further comprising compressing the locking portion of the secondconnector; flexing the second securing portion of the housing upon thecompressing; withdrawing the second connector from the second opening;and decoupling the second connector from the second coupler.